sun rise qc torque

7/26/2019 Sun Rise Qc Torque

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SUN RISE

QUALITY CIRCLETR UNIT

HEELS INDIA LIMITED


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Leader

Member

Facilitator

Member

MemberNagendran. R Kannan.V

Member

Poosadurai.T

TEAM MEMBERS


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Theme:

TO ELIMINATE CUSTOMERCOMPLAINT DUE TO LOW TORQUE

PROJECT START DATE :05.05.2013

PROJECT END DATE :25.08.2013

PROJECT MEETINGS :Mo!"#

NO O$ MEETINGS %ELD :12

ATTENDANCE :85 &

ABOUT OUR SUN RAISE QC


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Step-1 Identifcation O Problem

TypeAMinimum involvement of other Department in Solving Them /Can be solved by the QCC Member itself

Type B - nvolvement of other Department is a ne!essity

Type C "roblems !an be solved #ith Management assistan!e

Sl. No. Problem Descriptrion

A B C

1 Wrong Assembly position P

2 Bolt twist P

3 Bolt nut Lossened Condition P

4 Wrong rim/ Disc assembly P P

Low !or"ue P

# Double wa$ser Assembly P

% Blow &ole / 'orosity P

( Bolt &ole damage P

) *+cess ,un -ut P P

1. Lug inset problem P


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Ranking

1 - Low 2 - Moderate 3 - High

Total Marks Formula = Multiplication (!"!#!$!%!M&

S .No LineMachine /Operation

Identified problem / issues

Ranking Related to

Total marksP ! " S M

1 Assembly Manual Wrong Assembly (Position) 3 1 1 1 1 1 3

2 Assembly Manual Bolt twist 1 2 1 1 1 1 #

3 Assembly ManualBolt nut LossenedCondition

1 2 2 1 1 1 $

4 Assembly ManualWrong rim Disc !ssembly

3 2 1 1 1 1 %

5 Assembly Manual Low tor"e 3 2 3 2 3 1 108

6 Assembly Manual Double w!#ser Assembly 2 3 2 2 1 1 #$

7 Lug Weld Primo Blow $ole Porosity 3 1 2 2 1 1

8 Oters Oters Bolt $ole d!m!ge 1 3 2 1 1 1 %

! Assembly Manual %&cess 'un ut 2 3 2 1 1 1

10 Painting Manual Lug nset *!ri!tion 1 3 2 1 1 1 %

ro'lem categor)*ssem'l related

Step-2 Selection O Problem


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Problem Definition:


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P,- D%N% +$% P'BL%/

RIM

MFGINTERNAL

STORAGE

LUG

WELDED

RIM AND

DISC

ASSEMBLY

DISC

MFG

LUG

WELDING

INTERNAL

STORAGE

LOADING TO

DESPATCDESPATC

Problem !oi"t

CED

PAINTING

PAC#ING

AS S P'C%SS

PC FINIS

PAINTING

CED

PAINTING


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STEP-4 ANALYSIS THE PROBLEM


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IMPORTANCE / EFFECT OF TE PROBLEM

This is a irritating potential customercomplaint at Tractor export assembly

This may also affect other product soWheels India brand name will lost

Wheels may have to be scrapped andreplaced

IMPORTANCE OF TE PROBLEM


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B$ %&i"' (W ) *

Prod%ctio" lo&&+ Re,or-

co&t i"crea&e.

Problem Definition using W ! "

Lo, Tor/%eWAT i& t0e Problem1

Tractor E2!ort a&&embl$WERE doe& t0i&!roblem occ%r1

Rim ) Di&c A&&embl$WEN doe& it occ%r1

WO "otice t0i&

!roblem1

I"&!ector

OW m%c0 i& t0e

&e3erit$1


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B$A% ST&$M%'

TOTAL NO.OF POINTS4*5

-5 Identiying the CausesS.No List o0 c!uses

1 Low !ir pressure

2 Nut 'unner inconsit!ncy

- 3ns4illed oper!tor

5 Bolt 6 Nut t#re!ds worn out

7 $ig#t D

8 Wrong lug welding inset9 Wrong 'im : Disc !ssembly position

; Wrong position o0 bolt : nut

< Wrong lug si=e

1> Wrong bolt : nut !ssembly

11 Wrong rim code m!r4ing

12 Wrong disc code m!r4ing

1- ncorrect Assembly ?&ture


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/!n

/!teri!lsMethods

Machine

CA(S) * )++)CT DA'$AM /+S, B&%) DA'$AM /S,A.A DA'$AM

N PSSBL%CA3S%S @

1-

Various form

depthWrong location ofmarking

Wrong lug welding

Wrong rim code marking

Wrong disc code marking Wrong disc supply

Wrong Lug welded rim supply

Wrong lug

Wrong Lug welded

Rim & isc

assem!ly position

Wrong position

of nut & !olt

Wrong !olt & nutassem!ly

Wrong lug

welding inset

"ntrained person

#ncorrect $ssem!ly fi%ture


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Method +or Considering Causes for alidation


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/!n

/!teri!lsMethods

Machine

CA(S) * )++)CT DA'$AM

Wro"'A&&embl

NO OF

IMPORTANT

CAUSES 46

Wrong Lug welded Rim &

isc assem!ly position

Wrong Lugwelded rimsupply


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STEP 7 w$y w$y analysis

W0$1

W0$1

W0$1

Co%"ter mea&%re

Wrong assem!ly

Wheels offset changed

isc position changed

Wrong isc

A" arra"'eme"t to 7i"d o%t t0e o77&et o7

7la"'e d%e to Wro"' a&&embl$ to be

!ro3ided


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P'BL%//P'%,

/%N+

B%'% A+%'

There was no proision tofind out the wrongassem!ly

$ flag like arrangementproided to find thewrong assem!ly

Step-8 Developing Solution


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ep-9 Foreseeing Probable Resistan

NoR

esista

nce


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Step-10 Trial Implementation

Sl. NoTrial Date

Process /machine /

Detail of thetrial

No. of QtyTrial taken

Qty Accepted QtyRejected

Final result

125.07.2012 to

27.07.2012

ExportAssembly Wheels have

been assembledto

1500 1500 0

P!A "!E#mplemented is

$or%in& in &ood'ondition.

TRIAL ACCEPTEDTRIAL ACCEPTED


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Standardi0ation1. 2 3 ,

(. ) W*AT W*" W* W*E+E W*E) *W

1 Wron& Assembly

+im dis'assemblyo,,set d-e to

$ron& partassembly

/A Export Assembly A-& 2012

A P!A "!E $ithsensin&arran&ements have

been p-t in pla'e toidenti,y the $ron&assembled $heels.

11 Regular Implementation

T0i& PO#A YO#E i& added i" t0e e2i&ti"' PO#A YO#E Ma&ter li&t a"d bei"'

Mo"itored i" o" dail$ ba&i&.


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$ori=ont!l

Deploymentame type o0 system $as been planned toDomestic !ractor Assembly


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p-12 Follow p !"onitoring # Revi


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'D Customer complaints $ae been eliminated in *+portassembly

,ewor due to wrong assembly $as been eliminated5

,ewor operators 0atigue $as been eliminated5

-n time deliery

a0ety issues during o6ine rewor $as been eliminated

Bene7ts


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COST BENEFITS

E2ter"al Sa3i"'&8C%&tomer com!lai"t9

Replacing cost per wheel "'()*+++

Total cost #NR ,-,+-+++

I"ter"al &a3i"'&

Laa!our cost per wheel Rs.,

/onsuma!le cost per person Rs.0

1anpower for rework 2

Total wheels per year *++

Total cost +3++

Total cost saing45ear #NR ,-0+-3++

Total cost for complete the pro#ect

!l "o#t for "om$lete t%i# $ro&e"t'R#()*)+


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THANKS TO ALL

sun rise qc torque

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